summer 17 examination subject title: mechanical ...msbte.engg-info.website/sites/default/files/s17mo...

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION (Autonomous)

(ISO/IEC - 27001 - 2005 Certified)

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MODEL ANSWER SUMMER– 17 EXAMINATION Subject Title: Mechanical Engineering Materials Subject Code:

Important Instructions to examiners: 1) The answers should be examined by key words and not as word-to-word as given in the model answer

scheme. 2) The model answer and the answer written by candidate may vary but the examiner may try to assess

the understanding level of the candidate. 3) The language errors such as grammatical, spelling errors should not be given more Importance (Not

applicable for subject English and Communication Skills. 4) While assessing figures, examiner may give credit for principal components indicated in the figure. The

figures drawn by candidate and model answer may vary. The examiner may give credit for any equivalent figure drawn.

5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values may vary and there may be some difference in the candidate’s answers and model answer.

6) In case of some questions credit may be given by judgement on part of examiner of relevant answer based on candidate’s understanding.

7) For programming language papers, credit may be given to any other program based on equivalent concept.

Q. No.

Sub Q. N.

Answer Marking Scheme

1

a

b

c

d

Unit cell:-The smallest geometric repetitive unit of space lattice which repeats in all direction

to form the space lattice is known as unit cell.

Space lattice:-It is the three dimensional, regular, repetitive arrangements of atoms within a

single crystal of a crystalline material.

Properties of materials:-An engineer must have an intimate knowledge of the properties and

behavioral characteristics of the materials that he intends to use. While designing a product

you need to select materials to create the product. For selecting materials, you must assess the

properties of each material to ensure that the selected material is appropriate for

manufacturing the desired product. The understanding of the properties of materials is highly

essential because without this information & knowledge, the designing of manufacturing

process may be expensive & complex task

Definition of

i) Phase:-Any homogeneous, physically distinct and mechanically separable portion of a

system is known as phase.

ii) Solid solution:-Solid solution is microscopically homogeneous mixture of atoms of two or

more elements right down to atomic level, one of the element should be essentially a metal

and mixture shows metallic properties

Heat treatment:-Heat treatment process is used to change the external properties of material

by changing its internal microstructure. The external properties of material like tensile

strength, impact strength, ductility, hardness depends upon the internal microstructure of the

material. The internal microstructure can be change by using heat treatment process by

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1 Mark

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adopting different rates of cooling

Advantages of heat treatment:-

i)Relieving internal stresses developed during cold working,welding,casting,forging,etc

ii)Improve machinability and corrosion resistance

iii)change in grain size

iv)improve hardness, ductility and toughness

v)improve electrical and magnetic properties

Classification Of steel:-

i)Mild or Low carbon steel:- It contains 0.15 to 0.45% of carbon

ii)Medium Carbon Steel:- It contains 0.45 to 0.80% of carbon

iii) High Carbon steel:- It contains 0.80 to 1.5% of carbon

Various quenching medias for heat treatment

i)Water

ii)Oil

iii) brine solution

iv)Air

v)Furnace cooling

Alloy steel:-Alloy steels are carbon steel with other metals added specifically to improve the

properties of steel significantly. common alloying elements are

chromium(Cr),Nickel(Ni),Maganese(Mn),Silicon(Si),Vanadium(V),Molybdenum(Mo),Tungs

ten(W)

Examples:-Stainless steel, Tool steel, Free cutting steel, shock resisting steel, Heat resisting

steel, spring steel

Types of cast iron

i)White cast iron

ii) Gray cast iron

iii) Malleable cast iron

iv)Nodular cast iron

Properties of copper • Highly ductile and posses fcc crystal structure.

• density is 8920 kg/cu.m

• melting point 1083 ºC

• Higher thermal & electrical properties.

• Corrosion resistance.

• Non magnetic and pleasing color.

• It can be welded, brazed and soldered. i.e. ease of fabrication.

• Good machinability.

Applications of copper Roofing, gutters radiators, gaskets, kettles, pressure vessels, distillery condenser and heat exchanger applications, bolts, studs, welding tips, contact pins, switch gears, relays and precision electrical equipments.

Any two

advantages

1/2 mark each

2 Mark

Any Four

quenching

media 1/2

Mark each

1 Mark

Any two

examples 1/2

Mark each

1/2 Mark for

each

Any two

properties 1/2

Mark each

Any two

applications1/

2 Mark each



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Properties of Aluminum:-

i)It is ductile & malleable due to its FCC structure

ii)It is light in weight

iii)It has very good thermal and electrical conductivity

iv)It has excellent corrosion & oxidation resistance

v)It is non magnetic

vi)It has silvery white colour

vii)It can be alloyed with other metals

viii)It can be cold worked and also hot worked

A Polymer is a chemical substance made up of repeating units or molecules to form a long

flexible chain.

Poly means many and mer means a unit. Polymeric materials are composed of a number of

small units called monomers connected with each other

Examples:-Plastics,rubber,polyvinyl chloride(PVC),polystyrene,ABS, Polyster resins, Epoxy

resins, silicon resins

Non metallic materials & their applications:-

i)Polymers:-Toys,combs,hoses,pipes,telephone receivers, electric plugs, TV cabinets, camera

body

ii)Rubbers(elastomers):-Pneumatic tyre & tubes, heels and soles,gaskets,belts,shoe, flooring,

seals,O-rings

iii)Ceramic:-Porcelain,pottery,brick, glass,diamond,garnet,silicon carbide,asbestos,

rocks,cement

iv)Insulating materials:-stoppers, Roofs and partition, brake linings, for refrigerators, furnaces

Application of powder metallurgy:-

i)Porous products eg,bearing and filters

ii)Automotive components such as electrical contacts, crankshaft drive, piston rings,

connecting rods and brake linings

iii)Products of complex shapes that require considerable machining when made by other

processes eg.gears

iv)Products where the combined properties of two metals or of metals and non metals are

desired non –porous bearings, electric motor bushes

v)clocks and timing devices,typewriters,adding machines,calculators,permanent magnets

vi)Grinding wheels

vii)Refractory parts made of tungsten and molybdenum are used in electric bulbs,X-ray

tubes,cathode,anode

viii)Atomic energy applications

Advantages of non destructive testing:-

i)The component does not break or damage even after testing the product

ii) Internal /external defects, flaws can be detected.

ii)These tests are more reliable, safe and economical

iii)These are extremely useful in revealing defects in components like cracks,porosity

,inclusion,blow holes,flaws,cavities

Any Four

properties 1/2

Mark each

1 Mark

Any two

examples

1/2marks

each

1/2Mark for

each non

metallic

material & 1/2

Mark for each

applications

Any Four

applications

1/2 Mark each

1/2 Mark

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iv)These are more accurate

Packing efficiency:-The fractional amount of volume or space occupied by atoms in an unit cell

is called atomic packing efficiency. The packing arrangement of atoms depends on the relative

radii of the atoms involved and also on the character of bonding between atoms

Packing efficiency=Volume of atoms in unit cell Volume of the unit cell

Ductility:-

It is the property of material by virtue of which it can be drawn into thin wires.

OR

It is the capacity of a material to undergo under tension without rupture

Plasticity:-It is the ability of material to be permanently deformed without fracture even after

the load is removed. It is the property of material, which retains the deformation ,produced

under load permanently

Density:-Density of material is defined as the mass per unit volume of the material

Strength:-It is defined as the capacity of material by virtue of which it can withstand an

external force

1 Mark

Calculation of

packing

efficiency of

BCC unit cell

3 Mark

1 Mark

1 Mark

1 Mark

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Substitutional solid solution:

• Here the atoms of two elements are nearly same in size & substitutes each others position in space lattice. • They have nearly same size

• Same electrochemical nature

• Solution has lower valancy.

interstitial solid solution: • here iron atoms are large in size and number and basic space lattice is of iron.

• carbon atoms are small in diameter and occupies interstitial space between two larger iron atoms.

Cu-Ni binary system:-

Isomorphous system is formed by the elements which are completely soluble in liquid as well

a solid state. Extreme left line on diagram shows 100% Cu whereas extreme right hand line

shows 100% Ni.As we move from left to right Ni percentage increases. Melting point of Cu is

1085 degree C while 1455 degree C for Ni.Above liquidus line both elements are completely

1 Mark

1 Mark

2 Mark for

each sketch

Neat sketch of

Cu-Ni system

2 marks

Explanation-2

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soluble in each other and exists in liquid state. Below solidus line both elements are

completely soluble in each other and exists in solid state α.In between solidus and liquidus

line the state is α+L.

i) To increase hardness, wear resistance and cutting ability of the steel.

ii) To alter the physical, mechanical or chemical properties of steels

iii) To reduce or eliminate internal residual stresses.

iv) To modify grain size of the steel

v) To improve ductility & toughness

vi) To improve electrical and magnetic properties

vii) Improve machinability

Viii) Increase corrosion resistance of the steel

TTT diagram:-On X axis Log time scale is provided and on Y axis temperature scale is

provided. There are two horizontal lines on diagram, upward line is called as Ms temperature

line i.e. start of martensite temperature transformation line and lower line is called Mf line i.e.

finish of martensite transformation line. At extreme top horizontal line is there called as Ac1

line at 723 degree C.As we down the pearlite becomes more and more fine and hardness of

the steel increases. As the percentage of the carbon in steel increases, the nose of TTT

diagram shifts in rightward direction. The left curve in the diagram represents start of pearlite

and right curve indicates finish of pearlite. In the upper right region coarse and fine pearlite is

obtained, in the intermediate region upper and lower banite is obtained and in the bottom

region martensite is obtained .In between two curves austenite, ferrite and pearlite exists.

Depending upon the cooling rate various transformation products are obtained on the

diagram.

Any Four

objectives 1/2

Mark each

Neat sketch-2

Mark

Explanation-2

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a)

b)

Attempt any four.

Give the detail classification of engineering materials.

Explain lead and tin binary eutectic system with neat sketch.

1 mark for each type(any four)

Sketch 2m, description 2m.

Lead(Pb) and Tin (Sn) Binary eutectic system



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d)

• It is the alloy system between two metals lead and tin which are completely soluble in liquid stage but completely insoluble in solid stage and showing eutectic reaction.

• Eutectic mixture found at a temperature of 183 degrees Celsius. And composition of eutectic is 62 % tin and 38 % lead.

• At this temperature molten lead and tin directly solidifies as a eutectic of both elements.

What are various phases exist on Fe-Fe3c diagram?

Ferrite: α- alpha solid solution

It is an interstitial solid solution of carbon dissolved in α-iron.(BCC- structure.). Maximum solubility of carbon is 0.008 % at room temp. and this solubility limit increases up to 0.025 % at 723 0c.

Cementite : (Fe3C)

called as iron carbide, CM, fe3c. Cementite contains 6.67 % C by wt. It is a intermetallic stable carbide compound. Crystal structure is orthorhombic. Very very hard and brittle interstitial compound.

Austenite :γ –gamma solid solution.

It is an interstitial solid solution of carbon dissolved in ŗ gamma iron ( FCC structure). solubility of C is 0.8% at 723 0c and this limit increases up to 2 % at 1140 0c.

Pearlite: ( ferrite + cementite) austenite transforms to pearlite on very slow cooling. In an eutectoid steel ( 0.8%C steel) austenite transform to pearlite at 723 0c. Pearlite shows alternate plates of ferrire and cementite. Ledeburite: (r + Fe3C) It is an eutectic mixture of austenite and cementite contains 4.3% C at 1140 0c.

Define annealing. State the effects of annealing on properties of steel.

Annealing may be defined as the heat treatment process in which the given steel is heated to annealing temperature range, hold for some time and there after cooled slowly in the furnace by switching off the furnace leading to formation of coarse pearlitic structure in the steel.

• It improves homogeneity of steel. • It alters microstructure of steel. • it restores ductility. • refines the grain size. • relieves the internal stresses in steel. • imroved machinability of steel. • It reduces strain hardening effect of cold working. this increases ductility.

1 mark each with suitable description.(any four)

Definition 1 m,

Effects 3 m



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e)

f)

a)

State the effect of following elements on steel. i) Nickel ii)molybdenum iii) chromium iv) tungsten

Nickel : Provides strength, stability and toughness. Higher amount of Ni stabilizes austenitic structure at room temperature. Helps in formation of free graphite. molybdenum : Usually < 0.3%

increase hardenability and strength Mo-carbides help increase creep resistance at elevated temps

typical application is hot working tools. chromium : Usually < 2%

increase hardenability and strength Offers corrosion resistance by forming stable oxide surface typically used in combination with Ni and Mo.

tungsten : helps to form stable carbides

increases hot hardness. used in tool steels. What is 18-4-1 tool steel? State its application.

It is high speed steel having following composition. 18% tungsten, 4% chromium, 1% vanadium. These are high alloyed tool steels developed initially to do high speed metal cutting. Now, they used in a wide variety of machining operations. These are characterized by high hardness (60-65 HRC at 600-650°C), high red hardness, wear resistance, reasonable toughness and good hardenability. Applications :

End mills, drills, lathe tools, planar tools. Punches, reamers, Routers, taps, saws.

Broaches, chasers, and hobs. Attempt any four.

Draw a neat sketch of iron-iron carbide equilibrium phase diagram.

1 m each.

Composition 1m,

Description 1m,

Applications 2m.

Labeled sketch 4m



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What is normalizing? State its purpose & explain how normalizing is carried out.

Normalizing is the heat treatment which involves heating of the given steel to “austenite temp. range” holding it & there after cooling to room temperature at slow rate of cooling, generally “air cooling”. purpose:

• To eliminate coarse grained structure. • To reduce segregation. • To refine grain structure. • To produce harder and stronger steel than annealing. • To obtain required mechanical properties. • To relieve internal stresses in some cases.

Process: A typical normalizing process involves following steps,

1. Heating of steel: here the steel, depending upon its type is heated to the normalizing temperature range. For plain carbon steel this range is,

Ac3 + 50 for hypo eutectoid steels. Ac1 + 50 for eutectoid steel. Acm + 50 for hyper eutectoid steels.

For various alloy steels the normalizing temperature range is around 780 to 850 0c, depending upon the type of steels. 2. Holding of steel: here the steel is kept at this normalizing temperature for some time for equalization of temperature depending upon the weight and area of steel part. 3. Cooling of steel: here the steel is cooled from this normalizing temp. To room

Definition 1m,

Purpose 1m, process 2m.



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temperature with a slow rate of cooling in the “air”. Here the austenite in the steel is transformed into the “ fine pearlite structure” The air cooling used may be still air cooling or Forced air cooling.

Define hardening. Explain how hardening is carried out.

Hardening of steel may be defined as process of imparting hardness, wear resistance and abrasion resistance to steel. Process :

• Process consists of heating the steel to “hardening temperature range” , holding

there for some time and followed by quenching it in water or oil to get martensitic hard structure in the steel.

• Heating of steel: here the steel depending upon its type is heated to austenitizing temperature. this temp. Range is called as “hardening temperature range”.

Ac3 + 50 for hypo eutectoid steels. Ac1 + 50 for eutectoid steel. Ac1 + 50 for hyper eutectoid steels

• Holding of steel: here the steel is hold at this temperature for some time for equilization of temperature.

• Cooling of steel: here steel is cooled from austenizing temperature to room temperature in a suitable cooling medium with the cooling rate which exceeds the “critical cooling rate” so that austenite gets transformed into hard and brittle “martensitic structure”. due to formation of martensitic structure the hardness of steel increases.

Definition 1m,

Process 3m.



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e)

f)

What is stainless steel? State the properties and applications of stainless steel.

Stainless steel: It is an alloy steel containing higher amount of Cr and Ni. High degree of corrosion resistance and chemical resistance. Mostly used for heat resisting applications. Cr makes surface passive by forming surface oxide film. But for forming film it should be in contact with oxydizing agent. Ni is added to form this film in weak oxydizing environment. Generally cr 12 % and ni 8 % Properties :

o High corrosion resistance. o Non magnetic in nature. o Higher hardness and tensile strength. o Can Not Be Hardened By Heat Treatment.

Applications : o pressings o chemical and food pressing equipments o air craft exhaust manifolds o boiler shells o shafts o valves etc.

What is muntz metal? State its properties and applications. Muntz metal is brass having composition as 60% cu & 40% zn. properties : high strength, corrosion resistance. excellent hot working properties. applications : sheets for ship sheathing, condenser heads, Perforated metals, architectural work, valve stems, brazing rods, condenser tubes.etc. What is brass? State the properties and applications.

Brass is an alloy of Cu and Zn. By varying amount of Cu and Zn different brasses can be developed. It is a substitutional alloy. Different brasses are-

Muntz metal, Naval brass, Cartridge brass, Admiralty brass etc. Properties:

high strength, corrosion resistance. Malleable than bronze. excellent hot working properties. it has increased resistance to salt water corrosion. it has high conductivity and malleabilty. it has good cold working properties. Exhibits Low friction.

Description 1m,

Properties one & half mark,

applications one & half mark.

Composition 1m,

Properties 1m,

Applications 2m.

description 1m,

Properties 1 & 1/2 m,

Applications 1 & 1/2m.



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Applications:

Gears, bearings, ammunition casings and valves. Condenser plates, welding rods, propeller shafts, piston rods, valve stems. sheets for ship sheathing, perforated metals, architectural work, Brazing rods, condenser tubes.etc.

Evaporators, condensate coolers, heaters, water heaters, generator, air coolers.

Carburizing is a process of adding carbon to surface. This is done by exposing the part to

carbon rich atmosphere at the elevated temperature (nearly melting point) and allows

diffusion to transfer the carbon atom in the steel. Carburizing increases the carbon content

of the low carbon steel by a process of absorption and diffusion in order to produce a hard

case (surface).

Low carbon steel is heated in a carbon rich environment pack carbonizing packing in

charcoal or coke makes thick layer.

Gas carburizing use of propane or other gas in a closed furnace makes thin layer.

Liquid carburizing molten salt bath containing sodium cyanide barium chloride thickness

between the other two.

Followed by quenching hardness about 60 HRC is obtained.

*Methods:

1)Pack Carburizing

2)Gas Carburizing

3)Liquid Carburizing

*Applications:

1)In case hardening of gears .

2) Cam shafts .

3) Bearings

Surface Hardening:

In many engineering application it is desirable that steel being used should have a

hardened surface to resist wear and tear .At this time it should have soft and tough interior

or core so that it can absorb any shocks .e.g. Cam ,Gears etc.It can be heated above A3

temperature for hypo eutectoid steel and above A1 temperature for hyper eutectoid steels

by 50o C.

*Needs of surface hardening:

1) To Increase wear resistance

2)To Increase mechanical properties

3) To increase surface hardness

4) To Improve ductility

5) To Increase impact resistance

6) To Improve fatigue strength

7)To Rebuild worn or undersize part

8)To serve as an ornamental finish.

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Differentiate between White Cast Iron and Gray Cast Iron

Sr.

No.

White Cast Iron Gray Cast Iron

1 It is an alloy of Carbon

chemically bounded with Iron

1.7% to 4.5% of carbon and0.5%

to 3% of silicon

It is an alloy of Carbon and

silicon with Iron.

2.5% to 4% carbon and 1% to

3% silicon

2 carbon is present in the form of

carbide of iron.

carbon is present in the form of

graphite flakes.

3 When fractured it shows bright

white fracture

When fractured it shows gray

appearance

4 Under normal condition it is

brittle and not machinable

It has better machinability

5 Used in cement mixers, in some

drawing dies, ball mills and

extrusion nozzles.

Engine cylinders, pump

housings, electrical boxes,

valve bodies and decorative

castings

Composition of

i)40Cr4Mo2:Free cutting steel having 0.4 % Carbon,1% Cromium and 0.2 %

Molybdenum

ii)FeE400:Plain Carbon Steel with Yield Strength 400 N/mm2

iii)45C10S18:Medium Alloy Steel with 0.45 % Carbon,1 % Mangenese,0.18

% Sulphur.

iv)40C8:Unalloyed steel with 0.4 % Carbon and 0.8 % Mangenese.

Desirable Properties of bearing material

1)They should have high fatigue strength.

4(Any four)

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2) They should have good corrosion resistance.

3) They should have high compressive strength.

4) They should be hard and wear resistant.

5) They should be low in cost and easily available.

6) They should have low coefficient of friction.

7)It must be tough,shock resistant and sufficient ductile.

8)The affinity between shaft and bearing material should be minimum.

Sr

no.

Thermoplastics Thermosetting Plastics

1 They are formed by addition

polymerization

They are formed by condensation

polymerization

2 They consist of long chain

linear polymers with negligible

crosslinks

They have three dimensional

network structure

3 The soften on heating and

harden on cooling

They do not soften on heating

once hardened and set

4 By reheating to a suitable

temperature they can be

softened reshaped and thus

reused.

They retain their shapes and

structure even on heating hence

they cannot be reshaped and

reused.

5 They are usually soft weak and

less brittle.

They are usually hard strong and

more brittle.

6 They are recycled from west. They cannot recycled from west

7 They are generally soluble in

some organic solvents.

Due to strong bonds and cross

links they are insoluble in almost

all organic solvents.

8 Typical uses are in toys for

kids, combs, insulating tapes.

Telephone receiver, television

cabins, camera parts

4Any four



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b

c

Compare Austempering and Martenpering

Sr

No.

Austempering Martempering

1 It is not hardening Process It is hardening Process

2 This process transforms

austenite to bainite.

This process transforms austenite

to martensite.

3 It is also called as a

isothermal quenching

It is also called as stepped

quenching or interrupted

quenching. marquenching

4 Quenching time in salt bath

is longer to get bainite.

Quenching time in salt bath is

shorter to get martensite.

5 Very few alloy steels are

subjected to this treatment

The process is very suitable for

high hardenable steels

6 Less warping and distorsion Better elongation and hardness

Suggest suitable steel for

i) Crankshaft of IC Engine :Medium-carbon steel alloys are

composed of predominantly the element iron, and contain a small

percentage of carbon (0.25% to 0.45%)

ii) Propeller shaft of truck: material with high torsional rigidity as well

as material that can take a lot of fatigue .We can use alloy 303 or

any low carbon steel with 10-18 % chromium and 5-8 % nickel.

iii) Car bodies:Galvanised and cold rolled steel

iv) Household Utensils:Stainless steel.

State properties and application of glass wool

*Properties

1) It provides excellent insulation against heat and cold.

2) They have very high tensile strength.

3) They can be performed to hold their shape without use of special

4Any four

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surface covering.

4) These products are limited to a maximum temperature of about 2000C.

*Applications:

1) Thermal and sound insulation in airplanes.

2) Furnace, ovens, water heaters, freezers.

3) Industrially glass wool blankets, blocks, and boards are used to reduce

losses of heat from pipes boilers.

4) Used in electrical insulation.

Acrylics:

It is a group of vinyl plastics which are most widely used in Polymethyl

Methacrylate (PMMA)

*Properties

1) It is much tougher than glass

2) It is low abrasion resistant

3) It is good electric insulator.

4) It is having high resistance to sunlight

* Applications

1) Sheets

2) Industrial building

3) Lenses

4) Display door signs

5)Sink baths

6) Sanitary wares

2

2

1

1



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Block diagram of Powder metallurgy

Powder Production

Blending or Mixing

Compacting

Sintering

Sizing

Inspection/Testing

Nondestructive testing

These are the tests which do not damage or reduce the service life of a

component.Usually these tests do not directly measure mechanical properties

such as tensile strengths,hardness but they are used to locate flaws,defects in

the components.They make the component more reliable,safe and

economical.

*Methods of NDT

1)Magnetic Particle Inspection

2)Dye Penetrant Test

3)Ultrasonic Inspection

4)Radiography

5)Eddy Current Inspection

6)Visual Inspection

01 mark for

each term

2

2

summer 17 examination subject title: mechanical ...msbte.engg-info.website/sites/default/files/s17mo...

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